Method for consolidating composite materials

Abstract

Fiber-reinforced resin composites or other materials are consolidated in a noncontact-frictionless manner through the use of a pressurized plenum chamber (20) of a fluid bearing (10). The fluid bearing (10) is flexible and floats relative to the material (16) to be consolidated so that ply drop-offs and other variations in the thickness or surface contour of the material are easily accommodated. While within the plenum chamber, the material is locally heated by radiant energy from a source (30) positioned within the chamber. This localized heating enables the material to solidify in cooler zones of the plenum chamber under a uniform pressure.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
       1. A method for consolidating composite materials with a fluid bearing, said fluid bearing having an inflatable cushion that surrounds a cavity, said cavity cooperating with an opposing surface to form a pressurizeable plenum chamber when said inflatable cushion is inflated, said method comprising the steps of: stacking at least two plies of composite material on a work surface;   inflating said fluid bearing and positioning said fluid bearing in opposed relation to said work surface to form said pressurizeable plenum chamber;   pressurizing said plenum chamber with fluid;   applying a load to said fluid bearing to develop a pressure in said plenum chamber; and   positioning said fluid bearing so that said inflatable cushion is spaced from said plies and so that said plenum chamber is in superposed relation to said plies and said work surface to apply the pressure in said plenum chamber to said plies without physical contact between said inflatable cushion and said plies.   
     
     
       2. The method of claim 1 further comprising the step of: heating said plies while applying the pressure in said plenum chamber thereto. 
     
     
       3. The method of claim 2, wherein said step of heating comprises irradiating said plies with radiant energy. 
     
     
       4. The method of claim 2, wherein said step of heating comprises applying magnetic energy to said plies to inductively heat said plies. 
     
     
       5. The method of claim 2, further including the step of causing relative motion between the fluid bearing and the plies while heating and applying pressure to the plies. 
     
     
       6. A method for laying composite tape with a fluid bearing, said fluid bearing having an inflatable cushion that surrounds a cavity, said cavity cooperating with an opposing surface to form a pressurizeable plenum chamber when said inflatable cushion is inflated, said method comprising the steps of: disposing said fluid bearing opposite a work surface, inflating said inflatable cushion to form said plenum chamber, and pressurizing said plenum chamber with fluid;   applying a load to said fluid bearing to develop a pressure in said plenum chamber;   laying the tape on said work surface; and   positioning said fluid bearing so that said inflatable cushion is spaced from said tape and so that said plenum chamber is in superposed relation to the tape laid on said work surface to apply the predetermined pressure in said plenum chamber to said tape so as to press said tape onto said work surface without physical contact between said inflatable cushion and said tape.   
     
     
       7. The method of claim 6, further including the step of: heating said tape while applying the predetermined pressure in said plenum chamber thereto.   
     
     
       8. The method of claim 7, wherein said step of heating comprises irradiating said tape with radiant energy. 
     
     
       9. The method of claim 8, wherein said step of hearing comprises applying magnetic energy to said tape to inductively heat said tape. 
     
     
       10. A method of laying composite tape with a fluid bearing, said fluid bearing having an inflatable cushion that surrounds a cavity, said cavity cooperating with an opposing surface to form a pressurizeable plenum chamber when said inflatable cushion is inflated, said method comprising the steps of: causing relative movement between a tape supply and a work surface to lay tape onto the work surface;   disposing said fluid bearing opposite said work surface, inflating said inflatable cushion to form said plenum chamber, and pressurizing said plenum chamber with fluid;   moving said pressurized plenum chamber over the tape laid on said work surface without physical contact between said inflatable cushion and said tape to press said tape onto said work surface.   
     
     
       11. The method of claim 10, further including the step of: heating said tape while moving the pressurized plenum chamber thereover.   
     
     
       12. The method of claim 11, wherein said step of heating comprises irradiating said tape with radiant energy. 
     
     
       13. The method of claim 11, wherein said step of heating comprises applying magnetic energy to said tape to inductively heat said tape. 
     
     
       14. A method for consolidating composite materials with a fluid bearing, said fluid bearing having an inflatable cushion that surrounds a cavity, said cavity cooperating with an opposing surface to form a pressurizeable plenum chamber when said inflatable cushion is inflated, said method comprising the steps of: positioning at least two plies of composite material on a work surface;   disposing said fluid bearing opposite said work surface, inflating said inflatable cushion to form said plenum chamber, and pressurizing said plenum chamber with fluid; and   moving said pressurized plenum chamber over the plies stacked on said work surface without physical contact between said inflatable cushion and said plies.   
     
     
       15. The method of claim 14, further including the step of: heating said plies while moving the pressurized plenum chamber thereover.   
     
     
       16. The method of claim 15, wherein said step of heating comprises irradiating said plies with radiant energy. 
     
     
       17. The method of claim 15, wherein said step of heating comprises applying magnetic energy to said plies to inductively heat said plies. 
     
     
       18. A method for consolidating composite materials with a fluid bearing, said fluid bearing having an inflatable cushion that surrounds a cavity, said cavity cooperating with a surface that is spaced therefrom to form a pressurizeable plenum chamber when said inflatable cushion is inflated, said method comprising the steps of: stacking at least two plies of composite material on a work surface;   disposing said fluid bearing in spaced relation to said work surface and inflating said inflatable cushion to form said pressurizeable plenum chamber;   pressurizing said plenum chamber with fluid;   applying a load to said fluid bearing to develop a pressure in said plenum chamber; and   positioning said fluid bearing so that said inflatable cushion is spaced from said plies and so that said plenum chamber is in superposed relation to said plies to apply the pressure in said plenum chamber to said plies without physical contact between said inflatable cushion and said plies.